Systems and methods for statistically analyzing welding operations

ABSTRACT

A welding system including a welding power source including power conversion circuitry adapted to receive primary power and to convert the primary power to a weld power output for use in a welding operation and a controller communicatively coupled to the welding power source are provided. The controller is adapted to determine a statistical signature of at least one parameter of a welding process and to utilize the statistical signature to determine at least one of an electrode type, an electrode diameter, and a shielding gas type during the welding operation.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Divisional Application of U.S. patent applicationSer. No. 12/971,881, entitled “Systems and Methods for StatisticallyAnalyzing Welding Operations”, filed Dec. 17, 2010, which is aNon-Provisional Patent Application of U.S. Provisional PatentApplication No. 61/293,070, entitled “Optimizing the Setting of aWelding System Using Real Time Statistical Analysis of Parameters of theWelding Process”, filed Jan. 7, 2010, both of which are hereinincorporated by reference.

BACKGROUND

The invention relates generally to welding systems and, moreparticularly, to systems and methods for statistically analyzing awelding operation.

Welding is a process that has become ubiquitous in various industriesfor a variety of types of applications. For example, welding is oftenperformed in applications such as shipbuilding, aircraft repair,construction, and so forth. During such welding processes, a variety ofcontrols are often provided to enable an operator to control one or moreparameters of the welding operation. For example, welding systems mayhave user controls and inputs to allow setting and adjusting ofparameters such as the weld process, filler metal or electrode,shielding gas, metal thickness, travel speed, arc force, electronicinductance, hot start, droop, and so forth. Such controls may allow askilled welder to set and adjust a welding system to operate in thedesired manner based on factors such as the electrode type, shieldinggas type, weld process, metal thickness, weld conditions, and so forth.

Adjusting and setting such controls on a welding system often requires awelding operator to possess knowledge and skill regarding how toproperly set and adjust the controls throughout the welding operation.Improper adjustment of the controls may adversely affect the weldingoperation, thus leading to undesirable side effects, such as increasedspatter, undesirable bead profile or penetration, and so forth, whichmay present difficulties for the operator to start and maintain the arc.Unfortunately, some welding operators may not have the necessary skillto properly adjust one or more of the controls provided on the weldingsystem. Accordingly, there exists a need for improved welding systemsthat overcome such drawbacks.

BRIEF DESCRIPTION

In an exemplary embodiment, a welding system includes a welding powersource including power conversion circuitry adapted to receive primarypower and to convert the primary power to a weld power output for use ina welding operation. The welding system also includes a controllercommunicatively coupled to the welding power source and adapted todetermine a statistical signature of at least one parameter of a weldingprocess and to utilize the statistical signature to determine at leastone of an electrode type, an electrode diameter, and a shielding gastype during the welding operation.

In another embodiment, a method of controlling a welding power sourceincludes initializing one or more default settings for the weldingoperation, establishing a welding arc between a welding electrode and aworkpiece, and monitoring at least one of a current waveform and avoltage waveform produced during the welding operation. The method alsoincludes determining, based on the at least one current and/or voltagewaveform, a statistical signature of the welding operation during thewelding operation and determining, based on the statistical signature,one or more desired settings for the welding operation.

In another embodiment, a controller for a welding power source isadapted to detect initiation of a welding process, to initialize adefault setting for one or more parameters for the welding process, toperform a statistical analysis on one or more weld parameter waveforms,and to determine the electrode type being utilized in the weldingprocess based on the performed statistical analysis.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 illustrates an exemplary welding system including a welding powersource and a controller disposed therein in accordance with embodimentsof the present invention;

FIG. 2 is a flow chart illustrating an exemplary control method that maybe utilized by the controller of FIG. 1 to control a welding process inaccordance with embodiments of the present invention;

FIG. 3A illustrates an exemplary current versus time plot for a shieldedmetal arc welding process for a first electrode type in accordance withembodiments of the present invention;

FIG. 3B illustrates an exemplary voltage versus time plot for a shieldedmetal arc welding process for a first electrode type in accordance withembodiments of the present invention;

FIG. 4A illustrates an exemplary current versus time plot for anexemplary welding operation in accordance with embodiments of thepresent invention;

FIG. 4B illustrates an exemplary logic signal versus time plot for anexemplary welding operation in accordance with embodiments of thepresent invention;

FIG. 4C illustrates an exemplary voltage versus time plot for anexemplary welding operation in accordance with embodiments of thepresent invention;

FIG. 5 illustrates a plot of exemplary statistically determined averageshort circuit durations versus weld current for electrodes of differentdiameters and types in accordance with embodiments of the presentinvention;

FIG. 6 illustrates an exemplary method that may be utilized by thecontroller to detect the type of electrode being utilized in the weldingoperation and to set one or more parameters suitable for use with thedetermined type of electrode in accordance with embodiments of thepresent invention;

FIG. 7 illustrates an embodiment of a current versus time plot that maybe generated during an exemplary welding operation when controlledaccording to the method of FIG. 6;

FIG. 8 illustrates an embodiment of a method that may be utilized byembodiments of the controllers disclosed herein to statisticallydetermine an electrode type being utilized and to compare the determinedtype to a preset electrode type;

FIG. 9 illustrates an embodiment of a method that may be utilized by anembodiment of a weld controller to perform one or more statisticaldeterminations regarding a GMAW or a FCAW welding operation during theoccurrence of such an operation;

FIG. 10 illustrates exemplary statistical signatures associated with avariety of weld wires composed of the same material and having differentdiameters in accordance with embodiments of the present invention;

FIG. 11 illustrates an embodiment of a short circuit duration versuswire feed speed plot showing exemplary statistical signatures associatedwith a given electrode being utilized in GMAW welding operations withdifferent shielding gases;

FIG. 12 illustrates an embodiment of a short circuit frequency versuswire feed speed plot showing exemplary statistical signatures associatedwith a given electrode being utilized in a GMAW welding operation withdifferent shielding gases; and

FIG. 13 illustrates an embodiment of a method that may be utilized by acontroller to control a GMAW or FCAW process in accordance withembodiments of the present invention.

DETAILED DESCRIPTION

As described in detail below, embodiments are provided of weldingsystems including a controller adapted to optimize one or more weldsettings or parameters based on a statistical analysis of one or morewelding waveforms (e.g., a voltage waveform, a current waveform, etc.)or other suitable weld signals. In some embodiments, the statisticalanalysis yield a statistical signature for the welding process, and thestatistical signature may be utilized to determine the type ofelectrode, the type of filler metal, the type of shielding gas, and soforth, being utilized in the welding process. For example, in oneembodiment, the determined statistical signature may be compared to areference signature to make a determination regarding a weld parameter(e.g., the type of electrode). In some embodiments, the controller mayautomatically adjust one or more parameters or settings used in the weldprocess control based on the determined statistical signature. In otherembodiments, the controller may indicate to a user that a weld settingor input should be adjusted or may lock out further operation until thedesired adjustment is made to the identified settings or parameters.

In some embodiments, the statistical analysis performed by thecontroller may be utilized to distinguish between two or more types of aconsumable or device being utilized in the welding operation. Forinstance, the controller may be adapted to distinguish between two ormore types of welding electrodes or between two or more types ofshielding gas. For example, in some stick welding processes, thecontroller may be adapted to distinguish between a 6010 type electrodeand a 7018 type electrode based on the results of the statisticalanalysis. For further example, in some metal inert gas (MIG) weldingprocesses, the controller may be adapted to distinguish between use of asubstantially carbon dioxide shielding gas and an argon and carbondioxide mix of shielding gas. Indeed, in certain embodiments, thecontroller may be configured to distinguish between any suitable numberof possible consumables or devices being utilized based on thestatistical analysis.

Turning now to the drawings, FIG. 1 illustrates an exemplary weldingsystem 10 including a welding power source 12 and a controller 14disposed therein in accordance with embodiments of the presentinvention. In the illustrated embodiment, the welding power source 12includes a top panel 16, a front panel 18, and a side panel 20. The toppanel 16 includes a handle 22 and a strap 24 that may be utilized,independently or concurrently, to move the welding power source 12 fromone location to another, as desired by a welding operator. However, itshould be noted that in many embodiments, the welding power source 12may not be portable and may be configured for use in a single location.Indeed, any suitable welding power source may be utilized in accordancewith embodiments of the present invention, and the illustrated powersource is representative of a single, non-limiting embodiment.

The front panel 18 includes a control panel 26 including knobs 30 thatmay be utilized by an operator to set one or more parameters of thewelding operation. For example, in one embodiment, the knobs 30 or othercontrols located on the control panel 26 may be utilized by an operatorto set the desired welding current, voltage and/or wire feed speed.Still further, in some embodiments, other controls may be utilized by anoperator to select a welding process, adjust an arc force setting,adjust an electronic inductance setting, input an electrode diameter(e.g., 0.035″, 0.045″, etc.), input an electrode type (e.g., mildsteel), input a shielding gas type (e.g., 100% CO₂, 90% Ar with 10% CO₂,etc.), and so forth. Indeed, in various embodiments, the control panel26 may be utilized by an operator to set or adjust any suitable weldparameters or settings.

In the embodiment shown in FIG. 1, the front panel 18 also includes anegative weld output terminal 32, a positive weld output terminal 34,and a remote output terminal 36. The illustrated embodiment isconfigured for a stick direct current electrode positive (DCEP) weldingprocess. Accordingly, in the illustrated embodiment, an electrode holder38 is coupled to the positive weld output terminal 34 via cable 40, anda ground clamp 42 clamps a workpiece 44 and is coupled to the weldingpower source 12 via cable 46 to close the circuit between the weldingpower source, the electrode, and the workpiece during operation. Theremote output terminal 36 may be coupled to one or more remote controldevices configured to control one or more parameters of the weldingoperation from a remote location. For example, in some embodiments, theremote output terminal 36 may connect to a foot pedal control, ahandheld control device, a remote user interface, and so forth.

During operation, the welding power source 12 is configured to receiveprimary power, for example, from a wall outlet or a power grid, and toconvert the primary power to a power output suitable for use in thewelding operation. Accordingly, when in use, the controller 14 controlsone or more electrical components within the welding power source toproduce the desired output. For example, the controller 14 may beutilized to store and retrieve settings and parameters utilized for aparticular electrode type, filler metal type, shielding gas, and soforth. Further, the controller 14 may facilitate customization of thewelding parameters and settings by an operator by receiving and storingthe desired settings within a memory in the controller 14. Again, suchdesired setting or parameters may be communicated to the controller 14via the user interface 26 located on the welding power source 12.

Still further, as described in more detail below, while the weldingoperation is occurring, the controller 14 may be configured to perform astatistical analysis of one or more features of the welding operation todetermine one or more characteristics of the welding operation, whichmay be indicative of the electrode type, filler metal type, shieldinggas type, and so forth, being utilized. Further, the controller 14 maybe configured to distinguish between a predefined number of possibleelectrode types, shielding gas types, and so forth, during the weldingoperation. For example, in one embodiment, the controller 14 may performa statistical analysis of the welding current and voltage waveforms andmay utilize the results of such an analysis to determine an optimum setof operating parameters for the given setup of the welding operationbeing performed. Accordingly, in some embodiments, the controller 14 mayadjust parameters of the welding power source 12 during the weldingprocess to optimize operation for the detected condition. In otherembodiments, the controller 14 may alert the operator to an optimum setof conditions during the welding process, and the operator may thenadjust one or more parameters accordingly via the user interface 28.

FIG. 2 is a flow chart illustrating an exemplary control method 48 thatmay be utilized by the controller of FIG. 1 to control a welding processin accordance with embodiments of the present invention. The method 48includes the steps of initiating the welding process (block 50) andinitializing the weld controller to one or more default settings (block52). That is, in this embodiment, the controller implements a defaultset of parameters at the beginning of the weld process before astatistical analysis is performed. Indeed, the default startup set ofparameters may be preselected based on the most commonly used electrodefor the given welding process, the electrode previously used in the lastwelding operation that was performed, or any other desired criteria.

The method 48 also includes checking whether the welding arc isestablished (block 54), and, if not, the controller continues to monitorfor the initiation of a welding arc. When a welding arc is established,the controller determines a statistical signature for the weldingprocess (block 56). For example, the controller may statisticallyanalyze the voltage waveform and/or the current waveform during thewelding operation to determine a statistical signature. For furtherexample, in one embodiment, the controller may compare the generatedvoltage and/or current waveforms to one or more reference waveformsstored in the controller memory to determine the statistical signaturefor the welding process. Once the statistical signature has beendetermined, the controller may determine an electrode type beingutilized in the given welding operation (block 58) and may adjust orconfirm one or more weld settings being utilized in the weldingoperation based on the electrode type (block 60). However, it should benoted that in some embodiments, the controller may be configured todistinguish between two or more electrode types being utilized in thewelding operation (e.g., 6010 electrode type vs. 7018 electrode type).Such a feature may enable the controller to adjust one or more weldparameters during the welding operation to optimize performance of thewelding system for the given setup. It should be noted that although inthe embodiment of FIG. 2, the controller utilizes the statisticalsignature to determine an electrode type, the statistical signature maybe utilized to determine any of a number of parameters of the weldingprocess while the welding operation is occurring in other embodiments.

FIGS. 3A, 3B, 4A, 4B, and 4C illustrate an exemplary method that may beutilized by the controller to perform a statistical analysis of the weldcurrent and voltage waveforms to determine a statistical signature of awelding process while the welding operation is occurring. Specifically,FIG. 3A and FIG. 3B illustrate a current versus time plot 62 and avoltage versus time plot 64, respectively, for a shielded metal arcwelding (SMAW) process for a first electrode type (e.g., E7010, ⅛″diameter). In some embodiments, the controller may perform a statisticalanalysis on one or both of the current versus time plot 62 and thevoltage versus time plot 64 during the welding operation.

As shown, the current versus time plot 62 includes a current axis 66 anda time axis 68. Similarly, the voltage versus time plot 64 includes avoltage axis 70 and a time axis 72. As shown, the voltage plot 64includes a plurality of short circuit events 74, 76, 78, 80, and 82which occur during the welding operation and are interspersed withwelding arc periods 84, 86, 88, 90, 92, and 94. The short circuit events74, 76, 78, 80, and 82 may be characterized by a substantial drop involtage, as indicated on the voltage plot 64, during which time themolten end of the electrode has shorted to the weld pool. In certainembodiments, an arc period may follow a short circuit event after themolten ball has been drawn into the weld pool and an open arc has beenreestablished. The voltage plot 64 further includes transient shortcircuit events 96 and 98, which are characterized by a short duration ascompared to the short circuit events. Such transient short circuitevents may be a result of a molten ball on the welding electrodemomentarily touching the weld pool. Such events (e.g., 98) are oftenfollowed by a short circuit event of longer duration (e.g., 82) as themolten ball is drawn into the weld pool.

In some embodiments, the SMAW process may be carried out with a weldingpower source that utilizes an approximately constant currentcharacteristic (i.e., the output of the welding power source iscontrolled such that the output current remains at an approximatelyconstant value during the welding operation). In some embodiments, theknobs 30 or other suitable controls may be utilized by the operator toadjust or set the current value according to the requirements of thewelding operation. Still further, in certain embodiments, welding powersources that are utilized for the SMAW process may provide furthercontrol or modification of the current value during arc initiation,during short circuit events, during moments of high arc voltage, orother dynamic events that occur in the arc. For example, an arc forcecontrol may be provided, which causes the output current to increaseduring a short circuit event. Some arc force controls may have both astatic and dynamic characteristic. In such embodiments, the staticcharacteristic may control the steady state magnitude of the currentincrease during a short circuit event while the dynamic characteristicmay control the rate of change of the output current during a shortcircuit event as well as after a short circuit event. The static and/ordynamic arc force characteristics may be modified by varying one or morearc force constants. In some embodiments, an arc force constant may beused within a mathematical calculation, by a suitable circuit, software,or any other suitable device to modify the arc force characteristics.Some welding power sources may enable the operator to adjust the staticand/or dynamic arc force characteristics, such as with knobs 30.

One or more characteristics of the short circuit events 74, 76, 78, and80 may be a function of factors such as the type of electrode beingutilized in the welding operation, current setting of the power source,and so forth. For example, the duration of the short circuit or the timerequired for the short to clear may be affected by the static anddynamic arc force characteristics of the power source and may beindicative of weld parameters such as the electrode type. In theillustrated embodiment, in response to the detected short circuit events74, 76, 78, 80, and 82, the current plot 62 exhibits current spikes 100,102, 104, 106, and 108 due to the arc-force response to the shortcircuit events 74, 76, 78, 80, and 82.

In certain embodiments, the weld controller may statistically analyzecertain features of one or both of the current and/or voltage plots todetermine a statistical signature of the welding operation while beingperformed. For example, the statistical signature of a welding processmay include features such as the frequency of the short circuitoccurrences, the duration of the short circuits, and so forth. To thatend, the presence of a short circuit may be detected by the controller,for example, by comparing the instantaneous magnitude of the voltagewaveform to a threshold. For example, in certain embodiments, thethreshold may be a fixed value or a function of the average voltage.FIGS. 4A, 4B, and 4C illustrate an embodiment of such short circuitdetection logic.

Specifically, FIG. 4A illustrates an exemplary current versus time plot110, FIG. 4C is an exemplary voltage versus time plot 112, and FIG. 4Bis an exemplary logic signal versus time plot 114. The current plot 110includes a current axis 116 and a time axis 118. The logic signal plotincludes a logic signal strength axis 120 and a time axis 122, and thevoltage plot 112 includes a voltage axis 124 and a time axis 126. Asshown, a variety of short circuit events 128, 130, and 132 and transientshort circuit events 134 and 136 occur in the voltage plot 112. Thecurrent plot 110 exhibits a response to the short circuit events 128,130, and 132 with current peaks 138, 140, and 142. Similarly, the logicsignal plot 114 detects the short circuit events 128, 130, and 132 whiledisregarding the transient short circuit events 134 and 136. In such away, the controller may be configured to identify the short circuitevents 128, 130, and 132 by utilizing a duration threshold in additionto a voltage threshold. For example, as in the illustrated embodiment,if a short circuit duration does not exceed a predefined threshold, theevent is not detected by the logic signal 114 and, accordingly, may notbe utilized by the controller in a subsequent statistical analysis. Insome embodiments, the predefined duration threshold for detecting ashort circuit event and disregarding a transient short circuit event maybe between approximately 0.3 mSec and approximately 1 mSec. Further, itshould be noted that in additional embodiments, the controller may alsobe configured to disregard short circuit events that exceed a predefinedduration threshold, for example, short circuit events that result fromthe weld operator shorting the electrode to the work and are notindicative of one or more characteristics of the weld electrode. In someembodiments, the predefined duration threshold for disregarding shortcircuits, which may result from the weld operator shorting theelectrode, may be between approximately 50 mSec and approximately 100mSec.

In some embodiments, the controller may be configured to statisticallyanalyze one or both of the current plot 110 and the voltage plot 112during the welding operation to determine a statistical signatureassociated with one or more parameters of the welding operation. Thestatistical signature may include one or more statistical determinationsor calculations, such as average current, average voltage, average shortcircuit duration, percentage of short circuits that fall within a narrowtime window, short circuit frequency, standard deviations, RMS values ofvoltage or current, or any number of other suitable calculations. Insome embodiments, a narrow short circuit may be a short circuit with aduration that falls within a narrow time window, for example, with aduration that falls within an upper and lower duration threshold, asdescribed above. Further, in some embodiments, a narrow short circuitmay be defined as a subset of short circuit events. For example, in oneembodiment, a narrow short circuit may be defined as a short circuitwith a duration greater than approximately 1 mSec and less thanapproximately 5 mSec.

In one embodiment, the controller may statistically analyze the voltageplot 112 and the current plot 110 to determine the electrode type beingutilized in the welding operation. In such an embodiment, based on atleast one of the average current, the average short circuit duration,and the percentage of narrow short circuits, the controller maydetermine the electrode type. For example, the controller may comparethe obtained measurements and/or calculated statistical values to areference table to determine which electrode type exhibits the observedbehavior. The controller may utilize linear approximations, lookuptables, or any other suitable method to determine the electrode type.For instance, a 3/32″ E6010 electrode may be associated with an averageshort circuit duration which is substantially lower than that of a 3/32″E7018 electrode. For further example, a ⅛″ E6010 electrode may exhibit asubstantially greater percentage of narrow short circuits than a ⅛″E7018 electrode. Such differences in the statistically determinedcharacteristics of the welding operation may be utilized by thecontroller to determine, for example, the electrode type being utilized.

FIG. 5 illustrates a plot 144 of exemplary statistically determinedaverage short circuit durations versus weld current for electrodes ofdifferent diameters and types. The plot 144 includes an average shortcircuit duration axis 146 and a weld current axis 148. The plot 144further includes a first electrode type plot 150 and a second electrodetype plot 152. The first electrode type plot 150 includes a statisticalsignature associated with the first electrode type and a first diameter(e.g., 3/32″) 154, a signature associated with the first electrode typeand a second diameter (e.g., ⅛″) 156, and a signature associated withthe first electrode type and a third diameter (e.g., 5/32″) 158.Similarly, the second electrode type plot 152 includes a statisticalsignature associated with the second electrode type and the firstdiameter 160, a signature associated with the second electrode type andthe second diameter 162, and a signature associated with the secondelectrode type and the third diameter 164.

As illustrated, statistical differences based on the weld current andthe average short circuit duration may be utilized by the controller todetermine which electrode type and diameter is being utilized in thewelding operation. That is, in one embodiment, the controller maycompare the determined average short circuit duration and the weldcurrent level to a reference chart, such as the plots in FIG. 5, todetermine the weld electrode type and diameter. Although only two plotsare illustrated in the embodiment of FIG. 5, any number of plotsassociated with any desired number of possible electrodes may beprovided in the reference charts of additional embodiments. Further,once the electrode type and/or diameter is determined by the controller,one or more settings or parameters most suitable for use with thedetermined electrode type or diameter may be implemented for theremainder of the welding process. Still further, in some embodiments,the weld controller may utilize additional statistical values whendetermining the type or diameter of the electrode being utilized. Suchadditional values may include but are not limited to average voltagelevel, average or set current level, root mean square values of voltageand/or current, power, average arc duration (i.e., portion of thewaveform between short circuits), standard deviations of the measuredvalues, or any other suitable statistical parameter.

FIG. 6 illustrates an exemplary method 166 that may be utilized by thecontroller to detect the type of electrode being utilized in the weldingoperation and to set one or more parameters suitable for use with thedetermined type of electrode. The method 166 includes the step ofdetecting that a welding process has been initiated (block 168) andinitializing the weld controller to one or more default settings (block170). For example, before the welding operation begins and thestatistical analysis is performed, the parameters for the startup periodmay be default settings such as the settings associated with the lastelectrode type utilized in the machine, settings input by an operator,settings associated with the welding power source, or any other set ofdefault settings.

The method further includes the steps of verifying that a welding arc isestablished (block 172) and accumulating the short circuit duration forshort circuits with a duration in a predefined range (block 174). Thatis, for the short circuit events that are not determined to be transientshort circuits by the controller, the short circuit duration is tracked.Further, the accumulation of short circuit durations may continue untila predefined number of short circuits have been accumulated and/or untila predetermined time threshold has been exceeded. Still further, theaverage short circuit duration for the accumulated short circuits iscalculated (block 176). In this embodiment, the calculated average shortcircuit duration is compared to a threshold (block 178) to make adetermination as to which type of welding electrode is being utilized orto distinguish between two or more possible electrode types. If thecalculated average duration does exceed the threshold, the arc forceconstants are set according to a first parameter set associated with afirst electrode type (block 180). However, if the calculated averageduration does not exceed the threshold, the arc force constants are setaccording to a second parameter set associated with a second electrodetype (block 182). After adjusting the arc force constants based on theaverage short circuit duration, the controller may continue to monitorthe welding operation each time a welding arc is established todetermine whether or not a change in electrode type has beenestablished.

Such a method may be utilized by the controller to check the electrodetype throughout the welding operation while the welding operation isoccurring and to set parameters of the welding process according to thedetermined electrode type. Further, if an operator switches theelectrode type during the welding operation, embodiments of theillustrated method may be utilized to adjust the arc force constants tovalues appropriate for the current electrode being utilized. In such away, in some embodiments, the average short circuit duration may bedetermined by the controller and utilized as a statistical signature ofthe welding process in accordance with embodiments of the presentinvention.

FIG. 7 illustrates an embodiment of a current versus time plot 184 thatmay be generated during an exemplary welding operation when controlledaccording to the method of FIG. 6. Accordingly, the plot 184 includes acurrent axis 186 and a time axis 188. In this embodiment, during astartup period, the controller initializes one or more default settings,which are utilized until a statistical analysis is performed and anoptimized parameter set may be implemented based on the results of thestatistical analysis. As illustrated, for a first portion 190 of thewaveform, a default set of arc force constants associated with a defaultelectrode type (e.g., E6010) are implemented. During the first portion190 of the waveform, the average duration of the short circuit events isdetermined by the controller. In the illustrated embodiment, byanalyzing the average short circuit duration, the controller determinesthat a second electrode type (e.g., E7018) is being utilized, and thearc force constants are adjusted to produce the steady state portion 192of the current waveform. As such, according to the method of FIG. 6,embodiments of the presently disclosed controllers may alter one or moreweld parameters during the welding operation based on a statisticalanalysis.

FIG. 8 illustrates an exemplary method 194 that may be utilized byembodiments of the controllers disclosed herein to statisticallydetermine an electrode type being utilized and to compare the determinedtype to a preset type. Such a method may be utilized, for example, tosubstantially reduce the likelihood of a user operating a welding powersource while utilizing an undesired electrode. The method 194 includesthe steps of detecting that a welding process is initiated (block 196)and subsequently detecting the selected electrode type (block 198). Forexample, the selected electrode type may be the type of electrodespecified by the user via a control panel. The controller is furtheradapted to initiate the settings associated with the selected electrodetype (block 200) and to verify establishment of a welding arc (block202). Once the welding arc is established, the controller determines astatistical signature for the welding process (block 204) and determinesthe electrode type being utilized based on the statistical signature(block 206) as described in detail above.

The controller further performs a check as to whether the electrode typebeing utilized in the welding operation is the same as the electrodetype selected by the welding operator (block 208). If the selectedelectrode type matches the determined electrode type, the currentsettings are verified and the welding operation is enabled to continue(block 210). However, if the selected electrode type and the determinedelectrode type do not match, the welding operation is locked out (block212), and the welding operator is alerted to the presence of an error(block 214). However, in alternative embodiments, the welding operationmay not be locked out, but the welding operator may still be alerted tothe presence of an error. In such a way, the determined electrode typemay be utilized by the controller for a variety of desired purposes,such as to verify that the correct electrode is being utilized in thewelding operation.

FIGS. 9-13 illustrate embodiments of the present invention as applied togas metal arc welding (GMAW) and flux-cored arc welding (FCAW).Specifically, FIG. 9 illustrates a method 216 that may be utilized by anembodiment of a weld controller to perform one or more statisticaldeterminations regarding a GMAW or a FCAW welding operation during theoccurrence of such an operation. The method 216 includes detectinginitiation of a welding process (block 218) and implementing the defaultinitiation settings for the selected welding process (block 220). Themethod 216 also includes determining a statistical signature for thewelding process (block 222), as described in detail above for the SMAWprocesses. However, in this embodiment, the method includes utilizingthe statistical signature to determine one or more of the electrodetype, the electrode diameter, and the shielding gas type being utilizedin the welding operation (block 224). In some embodiments, if desired bythe operator, the controller may alter one or more weld parameters ofthe welding operation based on the one or more determinations (block226) and/or may alert the operator to the determinations and/or thesuggested weld parameters (block 228).

In embodiments of the present invention as applied to GMAW and/or FCAWsystems, the statistical analysis performed on one or more of thewelding waveforms may be utilized to determine the electrode type aswell as the shielding gas type being utilized during the weldingoperation. Such a determination may be utilized to determine suitableweld parameters, such as the dynamic and static behavior of the weldingsystem. As such, each electrode and shielding gas combination may beassociated with a unique set of desired settings. For example, it may bedesirable to control the dynamic behavior of the welding system with alower value of electronic inductance (i.e., the rate of change of theweld current) when welding with 100% CO₂ shielding gas as compared towelding with 75%Ar and 25% CO₂ as the shielding gas with the same typeof weld electrode. Indeed, a variety of weld settings may be adjustedbased on the particular combination of the weld electrode type and theshielding gas type detected.

FIG. 10 illustrates exemplary statistical signatures associated with avariety of weld wires composed of the same material (e.g., mild steel)but having different diameters. Specifically, FIG. 10 illustrates a weldcurrent versus wire feed speed plot 230 including a weld current axis232 and a wire feed speed axis 234 for an exemplary GMAW process. Asillustrated, the statistical signature for a first wire with a firstdiameter (e.g., 0.045″) 236 exhibits a different profile than thestatistical signature for a second wire with a second diameter (e.g.,0.035″) 238, which is different than the statistical signature for athird wire with a third diameter (e.g., 0.030″) 240. In someembodiments, by determining the weld current versus wire feed speedprofile of the occurring weld operation, the controller may determine,via comparison with the profiles 236, 238, and 240, the diameter of theweld wire being utilized. The controller may utilize additional inputsor measurements, such as weld voltage, as part of the profile todetermine the diameter of the weld wire being utilized. Subsequently, ifdesired, the controller may adjust one or more weld parameterspredetermined for use with the determined wire diameter.

FIG. 11 illustrates a short circuit duration versus wire feed speed plot242 showing exemplary statistical signatures associated with a givenelectrode being utilized in GMAW welding operations with differentshielding gases. The plot 242 includes an average short circuit durationaxis 244, a wire feed speed axis 246, a waveform 248 associated with afirst shielding gas type (e.g., 100% CO₂), and a waveform 250 associatedwith a second shielding gas type (e.g., 75% Ar and 25% CO₂). As shown,by determining the average short circuit duration during a weldingoperation and comparing to a reference average short circuit durationversus wire feed speed, the controller may utilize the statisticalcharacteristics of the welding process to determine the type ofshielding gas being utilized in the GMAW operation. For example, thecontroller may compare the average short circuit duration to one or morereference plots (e.g., 248 and 250) to determine the shielding gas type.It should be noted that although only two profiles associated with twotypes of shielding gas are illustrated in FIG. 11, any suitable numberof plots may be provided in alternate embodiments.

FIG. 12 illustrates a short circuit frequency versus wire feed speedplot 252 showing exemplary statistical signatures associated with agiven electrode being utilized in a GMAW welding operation withdifferent shielding gases. The plot 252 includes an average shortcircuit frequency axis 254, a wire feed speed axis 256, a first waveform258 associated with a first shielding gas type (e.g., 100% CO₂), and asecond waveform 260 associated with a second shielding gas type (e.g.,75% Ar and 25% CO₂). In this embodiment, by comparing the average shortcircuit frequency versus the wire feed speed, the controller maydetermine the type of shielding gas being utilized in the given weldingoperation. As before, additional shielding gas types may also beprovided on the plot 252 in other embodiments.

It should be noted that in some embodiments, one or more referencecharts may be utilized by the controller to determine and/or verify theshielding gas and/or electrode type being utilized in the GMAW or FCAWprocess. For example, in certain embodiments, the controller may utilizeboth the short circuit duration as well as the short circuit frequencyversus the weld wire feed speed to determine and then check that acorrect determination as to the type of shielding gas has been made.Still further, in other embodiments, the controller may first determinethe electrode type and, subsequently, may determine the shielding gastype. Additionally, in some embodiments, the controller may distinguishbetween two or more electrode types and may further distinguish betweentwo or more shielding gas types. Based on both determinations and/ordistinctions, the controller may then recommend or implement a suitableweld parameter set for the given welding operation. As before, thecontroller may dynamically analyze and control the welding operationwhile the operation is occurring.

FIG. 13 illustrates an exemplary method 262 that may be utilized by acontroller to control a GMAW or FCAW process in accordance withembodiments of the present invention. The method 262 includes detectinginitiation of the welding process (block 264) and implementing a set ofdefault initiation settings for the welding process (block 266).Further, the method 262 includes determining an average short circuitduration versus wire feed speed signature (block 268) and an averageshort circuit frequency versus wire feed speed signature (block 270) forthe given operation. Based on the determined signatures, the controlleris configured to determine the shielding gas type (block 272) asdiscussed in detail above.

Still further, the method 262 includes determining a current versus wirefeed speed signature (block 274) and, subsequently, determining thediameter of the electrode based on the determined signature (block 276).Again, such determinations may be made, for example, by comparing thedetermined statistical signatures to one or more reference signatures orcharts. In some embodiments, the controller may recommend one or moreweld settings to the weld operator based on the statistical analysis(block 278) and/or may alter one or more weld parameters based on suchdeterminations (block 280).

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

1.-6. (canceled)
 7. A method of controlling a welding power source,comprising: initializing one or more default settings for the weldingoperation; establishing a welding arc between a welding electrode and aworkpiece; monitoring at least one of a current waveform and a voltagewaveform produced during the welding operation; determining, based onthe at least one current and/or voltage waveform, a statisticalsignature of the welding operation during the welding operation; anddetermining, based on the statistical signature, one or more desiredsettings for the welding operation.
 8. The method of claim 7, furthercomprising alerting an operator to the one or more desired settingsbefore implementing the desired setting for the welding operation. 9.The method of claim 7, wherein the statistical signature is one or moreof an average short circuit duration, an average short circuitfrequency, a current versus wire feed speed profile, and a percentage oftotal short circuits that exceed a predefined threshold.
 10. The methodof claim 7, further comprising determining at least one of an electrodetype, an electrode diameter, and a shielding gas type based on thestatistical signature.
 11. The method of claim 7, wherein thestatistical signature is an average short circuit duration for aplurality of short circuit events, and the one or more desired settingsare determined by comparing the average short circuit duration to apredefined threshold.
 12. The method of claim 7, wherein the one or moredesired settings comprise at least one of a rate of change of current,an electronic inductance, a dynamic droop, a peak short circuit currentlevel, a lower limit arc current level, a voltage level, and a timedelay.
 13. The method of claim 7, comprising implementing the one ormore desired settings for the welding operation during the weldingoperation when the one or more desired settings are different than theone or more default settings.
 14. The method of claim 7, comprisinglocking out the welding operation when the one or more desired settingsfor the welding operation are different than the one or more defaultsettings.
 15. A controller for a welding power source, configured to:detect initiation of a welding process; initialize a default setting forone or more parameters for the welding process; perform a statisticalanalysis on one or more weld parameter waveforms; and distinguishbetween two or more electrode types to determine an electrode type beingutilized in the welding process based on the performed statisticalanalysis.
 16. The controller of claim 15, further configured todetermine a desired setting for the one or more parameters of thewelding process based on the determined electrode type.
 17. Thecontroller of claim 16, configured to deactivate welding when thedesired setting is substantially different than the default setting. 18.The controller of claim 16, configured to initialize the desired settingin place of the default setting when the desired setting and the defaultsetting are substantially different.
 19. The controller of claim 16,further configured to determine the presence or absence of a substantialdifference between the desired setting and the default setting and, whenthe presence of a substantial difference is detected, to alert anoperator to the presence of a detected error.
 20. The controller ofclaim 15, wherein the one or more parameters for the welding processcomprise one or more arc force settings.